Modern Mining January 2022

empty. Connected to a compressed air system, pneumatic tensioners are equipped with sensors that detect when the belt no longer has cargo and automatically backs the blade away, minimising unneces- sary wear to both the belt and cleaner. Additionally, it reduces labour for the constant monitoring and tensioning of blades to ensure peak performance. The result is consistently correct blade tension, reli- able cleaning performance and longer blade life, all managed without operator intervention. Power generation Systems designed to operate at high speeds over considerable dis- tances are generally powered only at vital locations such as the head pulley, disregarding adequate power for autonomous ‘smart systems,’ sensors, lights, accessories or other devices along the length of the conveyor. Running auxiliary power can be complicated and costly, requiring transformers, conduits, junction boxes and oversized cables to accommodate the inevitable voltage drop over long runs. Solar and wind can be unreliable in some environments, particularly in mines, so operators require alternative means of reliable power generation. By attaching a patented mini-generator to idlers and using the kinetic energy created by the moving belt, the accessibility obstacles found in powering ancillary systems can now be overcome. Designed to be self-contained power stations that are retrofitted onto existing idler support structures, these generators can be employed on virtually any steel roller. The design employs a magnetic coupling that attaches a “drive dog” to the end of an existing roller, matching the outside diam- eter. Rotated by the movement of the belt, the drive dog engages the generator through the outer housing’s machined drive tabs. The magnetic attachment ensures that electrical or mechanical overload does not force the roll to stop; instead, the magnets disengage from the roll face. By placing the generator outside the material path, the innovative new design avoids the damaging effects of heavy loads and fugitive material. The future Automation is the way of the future, but as experienced maintenance personnel retire, younger workers entering the market will face unique challenges, with safety and maintenance skills becoming more sophis- ticated and essential. While still requiring basic mechanical knowledge, new maintenance personnel will also need more advanced technical understanding. This division of work requirements will make it difficult to find people with multiple skill sets, driving operators to outsource some specialised service and making maintenance contracts more common. Conveyor monitoring tied to safety and predictive maintenance will become increasingly reliable and widespread, allowing conveyors to autonomously operate and predict maintenance needs. Eventually, specialised autonomous agents (robots, drones, among others) will take over some of the dangerous tasks, particularly in underground mining as the ROI for safety provides additional justification. Ultimately, moving large quantities of bulk materials inexpensively and safely will result in the development of many new and higher capacity semi-automated bulk transfer sites. Previously fed by truck, train or barge, long overland conveyors transporting materials from the mine or quarry site to storage or processing facilities may even impact the transportation sector. Stretching vast distances, these long bulk handling networks have already been built in some places with low accessibility but may soon be commonplace in many areas around the world. 

January 2022  MODERN MINING  41